Method of and apparatus for manufacturing molded materials of thermosetting resin composition

ABSTRACT

A method of manufacturing molded materials of a thermosetting resin composition in a method of granulating a molding material of the thermosetting resin composition, in which a sheet producing step for transferring the molding material in a molten state to a subsequent stage while processing the same material into a sheet type material of a predetermined thickness, a first processing step for cutting the sheet type material, which has thus been transferred to a stage for carrying out this step, in parallel with the transfer direction thereof to a predetermined width, and thereby obtaining a processed body of laterally arranged rows of elongated string-like materials, a step of cutting the processed body, which is obtained in the first processing step, to a predetermined length with respect to the transfer direction, a transfer direction changing step for transferring the processed body, which has been subjected to the cutting step, to a subsequent stage by changing the transfer direction of the processed body at 90 degrees with respect to the longitudinal processed body cutting line, and a second processing step for cutting the processed body, the transfer direction of which has been changed, in parallel with the processed body transferring direction to a predetermined width, and thereby obtaining granulated materials are carried out in order.

TECHNICAL FIELD TO WHICH THE INVENTION BELONGS

This invention relates to a method of and an apparatus for manufacturingmolded materials of a thermosetting resin composition, which includemelting and kneading a molding material of a thermosetting resincomposition containing a thermosetting resin, such as a phenol resin anda curing agent, and continuously granulating the resultant melt-kneadedproduct, and which rarely encounter the occurrence of fine powder duringthe transfer of the molding material from one stage to another and afterthe completion of the manufacturing of the granulated products.

RELATED ART

In a general related art method of granulating a molded material of athermosetting resin composition, raw materials are compounded, and theresultant product is then subjected to mixing, kneading and cooling, theresultant product being taken out as a massive or sheet type material,which is thereafter granulated by pulverizing the same to apredetermined grain size. However, in the pulverization step in thismethod, fine powder is liable to occur, and the granular moldedmaterials of a thermosetting resin composition obtained by this methodare also liable to generate fine powder even after the manufacturingthereof finishes, due to vibration occurring during the granulatedproduct manufacturing process. The fine powder occurring during themanufacturing process causes the yield of the products to decrease. Thefine powder occurring due to a vibrating force imparted to the productsduring the transfer thereof after the execution of packaging andshipping operations therefor floats as dust during the handling of theproducts, and is undesirable from the viewpoint of the environmentalsanitation. The granulating of the molding material of a thermosettingresin composition by an extrusion granulator comparatively rarelyencounters the occurrence of fine powder, and is desirable from theviewpoint of the environmental sanitation but the productivity is low.

The present invention has been made in view of the above-mentionedcircumstances, and provides a method of and an apparatus for granulatinga molding material of a thermosetting resin composition, capable ofeasily obtaining granular molded materials of a uniform grain size of athermosetting resin composition, capable of carrying out a continuousgranulating operation for a long period of time, having a highproductivity, and rarely encountering the occurrence of fine powderduring the transfer of the molding material from one stage to anotherand after the completion of the manufacturing of the granulatedproducts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a method of manufacturing molded products of athermosetting resin composition in an embodiment of the presentinvention;

FIG. 2 is a schematic diagram showing a processed body of laterallyarranged rows of elongated string-like materials obtained in a firstprocessing step;

FIG. 3 is a schematic diagram for having the shape of granulatedproducts understood easily which are obtained by cutting the processedbody of FIG. 2 in the cutting direction in a second processing step;

FIG. 4 is a schematic diagram showing a sheet type processed bodyobtained in the first processing step in third and fourth modes ofembodiment;

FIG. 5 is a schematic diagram showing sheet type processed body obtainedin the second processing step in the fourth mode of embodiment;

FIG. 6 is a drawing showing other mode of first grooved rolls and secondgrooved rolls; and

FIGS. 7 to 9 are partial sectional views describing modes of cuttingedges of the first grooved rolls and second grooved rolls.

MEANS FOR SOLVING THE PROBLEMS

The present invention (1) provides a method of manufacturing moldedmaterials of a thermosetting resin composition in a method ofgranulating a molding material of the thermosetting resin composition,in which a sheet producing step for transferring the molding material ina molten state to a subsequent stage while processing the same materialinto a sheet type material of a predetermined thickness, a firstprocessing step for cutting the sheet type material, which has thus beentransferred to a stage for carrying out this step, in parallel with thetransfer direction thereof to a predetermined width, and therebyobtaining a processed body of laterally arranged rows of elongatedstring-like materials, a step of cutting the processed body, which isobtained in the first processing step, to a predetermined length withrespect to the transfer direction, a transfer direction changing stepfor transferring the processed body, which has been subjected to thecutting step, to a subsequent stage by changing the transfer directionof the processed body at 90 degrees with respect to the longitudinalprocessed body cutting line, and a second processing step for cuttingthe processed body, the transfer direction of which has been changed, inparallel with the processed body transferring direction to apredetermined width, and thereby obtaining granulated materials arecarried out in order.

The present invention (2) provides the method of manufacturing moldedmaterials of a thermosetting resin composition according to the methoddescribed in (1) above, in which a second processing step for making amultiplicity of slits in the transfer-direction-changed processed bodyafter the transfer direction changing step has been carried out, inparallel with the transfer direction of the processed body to apredetermined width, and thereby obtaining a processed body oflongitudinally arranged rows of elongated string-like materials havinglongitudinal slits of a predetermined width, and a step of applying anexternal force to the processed body obtained in the second processingstep, and thereby obtaining granulated materials are carried out inorder.

The present invention (3) provides a method of manufacturing moldedmaterials of a thermosetting resin composition in a method ofgranulating a molding material of the thermosetting resin composition,in which a sheet producing step for transferring the molding material ina molten state to a subsequent stage while processing the same materialinto a sheet type material of a predetermined thickness, a firstprocessing step for making a multiplicity of slits in the sheet typematerial, which has been transferred to a stage for carrying out thisstep, in parallel with the transfer direction to a predetermined width,and thereby obtaining a sheet type processed body in which amultiplicity of longitudinal slits are formed, a step of cutting thesheet type processed body, which has been obtained in the firstprocessing step, to a predetermined length with respect to the transferdirection, a transfer direction changing step for transferring theprocessed bodies, which have been subjected to the cutting step, to asubsequent stage by changing the transfer direction of the processedbodies at 90 degrees with respect to the longitudinal processed bodycutting line, a second processing step for cutting the processed body,the transfer direction of which has been changed, in parallel with theprocessed body transferring direction to a predetermined width, andthereby obtaining a processed body of laterally arranged rows ofelongated string-like materials in which a multiplicity of lateral slitsare formed in a longitudinally spaced manner, and a step of applying anexternal force to the processed body of laterally arranged rows ofprocessed materials, which have been obtained in the second processingstep, and thereby obtaining granulated materials are carried out inorder.

The present invention (4) provides a method of manufacturing moldedmaterials of a thermosetting resin composition according to the methoddescribed in (3) above, in which a second step of making a multiplicityof slits after the execution of the transfer direction changing step inthe processed body, the transfer direction of which has been changed, inparallel with the transfer direction to a predetermined width, andthereby obtaining a sheet type processed body having generallychecker-patterned slits, and a step of applying an external force to thesheet type processed body obtained in the second processing step, andthereby obtaining granulated materials are included.

The present invention (5) provides an apparatus for manufacturing moldedmaterials of a thermosetting resin composition by granulating a moldingmaterial of the thermosetting resin composition, including rolling rollsfor rolling the molding material in a molten state into a sheet typematerial of a predetermined thickness, a first processing unit forprocessing the rolled sheet type material into a processed body oflaterally arranged rows of string-like materials of a predeterminedwidth, or into a sheet type processed body having a multiplicity ofslits extending in parallel with the sheet type material transferringdirection, a cutter for cutting the processed body, which has beenobtained by the first processing unit, in the processed bodytransferring direction to a predetermined length, a direction changingunit for changing the transfer direction of the processed body, whichhas been cut with the cutter, at 90 degrees with respect to thelongitudinal cutting line or slitting line of the processed body, and asecond processing unit for cutting or slitting the processed body, thetransfer direction of which has been changed by the direction changingunit, in parallel with the transfer direction thereof to a predeterminedwidth.

MODES OF EMBODIMENT OF THE INVENTION

The method of manufacturing molded materials of a thermosetting resincomposition in a first mode of embodiment of the present invention willnow be described with reference to FIG. 1 to FIG. 3. FIG. 3 is a drawingshowing the condition different from the actual condition. Actually,after a process carried out by second grooving rolls 6 a, 6 b hasfinished, a multiplicity of granulated materials fall scatteringly intoa recovery vessel as shown in FIG. 1. In this specification,“longitudinal direction” or “length” means or refers to transferdirection, while “lateral direction” or “width” means or refers to adirection crossing the transfer direction at right angles. Accordingly,the “width” of a molded material in the first processing step is turnedinto “length” in the second processing step. An apparatus 10 formanufacturing molded materials of a thermosetting resin composition,which embodies the manufacturing method in the first mode of embodiment,includes a pair of rolling rolls 2, 2, a pair of first grooved rolls 3a, 3 b (first processing unit), a cutter 4, a direction changing unit 5,and a pair of second grooved rolls 6 a, 6 b (second processing unit).

The two rolling rolls 2, 2 are not specially limited as long as therolls are capable of rolling a molding material 1 a in a molten stateand obtaining a sheet type material 1 b of a predetermined thickness a.Rolling rolls provided with scrapers (not shown) for forcibly peelingoff the rolled sheet type molded material 1 b therefrom are preferableas the rolling rolls 2, 2 since such rolls can transfer the sheet typemolding material 1 b smoothly to a subsequent stage. The rolling rolls2, 2 are provided with temperature regulating units (not shown)constituting arbitrary structural elements capable of regulating surfacetemperature of the rolling rolls 2, 2 between normal temperature and130° C. Devices containing on the inner side of outer surfaces of therolling rolls 2, 2 heating circuits or heaters using hot water or steamas a heating medium can be used as the temperature regulating units.When the surface temperature of the rolling rolls 2, 2 is set in theabove-mentioned range, a cutting process and a slitting process in thefirst processing step and second processing step can be set easilypracticable without denaturing the molding material.

The paired first grooved rolls 3 a, 3 b are adapted to process therolled sheet type molded material 1 b into a processed body 1 c having amultiplicity of laterally arranged rows of elongated string-likematerials of a predetermined width b, and the rolls are provided intheir outer surfaces with a multiplicity of cutting edges 31 a arrangedat a predetermined interval b in the axial direction of the rolls. Inthis embodiment, a distance between free ends of the cutting edges 31 a,31 b which are opposed to each other of the first grooved rolls 3 a, 3 bis set to zero, while the height of the cutting edges 31 a, 31 b are allset larger than a/2. This enables the rolled sheet type molding material1 b to be formed into the processed body 1 c of laterally arranged rowsof elongated string-like materials 11 c of b in width and a in height.Since the first grooved rolls 3 a, 3 b are provided so that the axes ofthe rolls 3 a, 3 b become parallel to those of the rolls 2, 2, the sheettype molding material transferring direction is kept unchanged, and thesheet type molded material 1 b is not distorted. Grooved rolls providedwith scrapers (not shown) for forcibly peeling off the processed body 1c of the laterally arranged rows of elongated string-like materials 11 ctherefrom are preferable as the first grooved rolls 3 a, 3 b since theserolls can transfer the processed body 1 c smoothly to a subsequentstage.

The cutter 4 is adapted to cut the processed body 1 c of the laterallyarranged rows of elongated string-like materials, which are obtainedthrough the first grooved rolls 3 a, 3 b, to a predetermined length dwith respect to the transfer direction. Cutting the processed body 1 cto a predetermined length d enables the transfer direction of theprocessed body 1 c in a subsequent stage to be changed at 90 degreeswith respect to the direction in which the processed body 1 c hastheretofore been transferred. The predetermined length d to which theprocessed body 1 c is cut is equal to or somewhat smaller than aprocessing width of the second grooved rolls 6 a, 6 b. This enables theexecution of the cutting process or slitting process in the secondprocessing step.

The direction changing unit 5 is adapted to change the transferdirection of the processed body 1 c, which has been cut with the cutter4 and transferred thereto, at 90 degrees with respect to thelongitudinal cutting line of the processed body 1 c. Namely, thisoperation constitutes a method of receiving the processed body 1 c,which has been cut with the cutter 4 and transferred forward, on, forexample, a flat table 51, and further transferring the processed body inthe direction which orthogonally crosses the processed body receivingdirection. The direction changing unit 5 in the present invention is notlimited to this. The direction changing operation may be carried out byanother method. In this method, for example, the flat table 51 is formedso that it can be turned freely at 90 degrees, and the direction inwhich the processed body 1 c on the flat plate 51 is to face withrespect to the transfer direction thereof is changed by 90 degreeswithout changing the direction in which the processed body 1 c istransferred from the cutter 4.

The second grooved rolls 6 a, 6 b are adapted to cut the processed body1 c, the direction of which has been changed by the direction changingunit 5, in parallel with the transfer direction thereof to apredetermined width c. Grooved rolls having the same construction as thefirst grooved rolls 3 a, 3 b can be used as the second grooved rolls 6a, 6 b. Namely, the second grooved rolls 6 a, 6 b are provided withscrapers (not shown) for forcibly peeling off the granular moldedmaterials 1 d therefrom. The distance between free ends of cutting edges61 a, 61 b of the second grooved rolls 6 a, 6 b is also set to zero,while the height of the cutting edges 61 a, 61 b is all set larger thana/2. This enables the processed body 1 c of the longitudinal arrangedrows of elongated string-like materials 11 c to be processed intogranulated materials 11 d of c in width, b in length and a in height.Referring to FIG. 1, the second grooved rolls 6 a, 6 b are provided sothat the axes thereof cross those of the rolling rolls 2, 2 and firstgrooved rolls 3 a, 3 b at right angles thereto.

The method of manufacturing molded materials of a thermosetting resincomposition in a first mode of embodiment of the present invention willnow be described. In a method of granulating a molded material of athermosetting resin composition, the sheet producing step is a step ofintroducing the molding material 1 a in a molten state between the tworolling rolls 2, 2, and transferring the molding material 1 a whilerolling the same into a sheet type material having a thicknesscorresponding to that a of a final granulated materials. In this step,introducing the molding material 1 a melt-kneaded by a heating roll (notshown) to a temperature of 70 to 130° C., preferably to a temperature inthe range of 80 to 110° C. between the rolling rolls 2, 2 and rollingthe same, and setting the temperature of the sheet type material 1 balso to a temperature of 70 to 130°, preferably to a temperaturesubstantially equal to the temperature at which the molding material isintroduced between the rolling rolls 2, 2 are preferable since theseoperations enable the softness of the material needed for the processingoperation in a subsequent stage to be retained without degenerating thesheet type molding material. Therefore, rolling rolls the surfacetemperature of which can be regulated to a temperature between normaltemperature and 130° C. are preferably used. When the temperature of themolding material 1 a is too low, the material becomes liable to bebroken in some cases in the first processing step, and, when thistemperature is too high, the molding material sticks to the firstgrooved rolls 3 a, 3 b, and it becomes difficult to carry out a smoothprocessing operation. The molding material in a molten state is amolding material of a thermosetting resin composition melt-kneaded inknown kneading equipment, such as a kneading roll, a uniaxial extruder,a biaxial kneading extruder, a planetary kneading extruder, a cokneaderand the like. According to the above-mentioned rolling step, theprocessing operations carried out by the grooved rolls in the firstprocessing step and second processing step are stabilized, and themolding material is compacted. Moreover, granular molded materialsrarely deformed even due to an impact and friction which the materialsreceive in a later stage, and rarely encountering the occurrence of finepowder are obtained.

After the sheet producing step finishes, the first processing step iscarried out. The first processing step aims at obtaining (refer to FIG.2) a processed body 1 c of a multiplicity of laterally arranged rows ofcontinuous elongated string-like materials 11 c of a in thickness and bin width by introducing the sheet type material 1 b between the twogrooved rolls 3 a, 3 b, and cutting the sheet type material 1 b into amultiplicity of parts in the direction parallel to the transferdirection thereof to a predetermined width, i.e., to a width bcorresponding to the length of final granulated materials. The externalappearance of the processed body 1 c of the laterally arranged rows ofelongated string-like materials 11 c is like that of a so-called rigidframe. Since the distance between the free ends of the opposed cuttingedges 31 a, 31 b of the first grooved rolls 3 a, 3 b is zero, the sheettype molding material 1 b is cut in the longitudinal direction atintervals equal to those b of adjacent cutting edges 31 a, 31 a. Whenthe temperature of the sheet type molding material passed through therolling rolls in the sheet producing stage in the first processing stepis maintained at 70 to 130° C., preferable results are obtained sincethe cutting stability of the sheet type molding material is improved.Using the scrapers (not shown) when the processed body 1 c of thelaterally arranged rows of multiple elongated string-like materials 11 care sent out from the first grooved rolls 3 a, 3 b is preferable forsmoothly carrying out the transferring of the material to a subsequentstage.

After the first processing step finishes, the step of cutting theprocessed body obtained in the first processing step to a predeterminedlength with respect to the transfer direction thereof is carried out. Inthis embodiment, the processed body 1 c of the laterally arranged rowsof multiple elongated string-like materials 11 c which has subjected tothe first processing step is once received by the direction changingunit 5 provided with the flat table 51. The processed body 1 c is cut tothe length d in a position in the vicinity of an upstream side portionof the flat table 51 with respect to the processed body transferringdirection. Consequently, the processed body 1 c of the laterallyarranged rows of the elongated string-like materials 11 c of a inthickness, b in width and d in length can be obtained.

After the cutting step finishes, the transfer direction changing stepfor transferring the processed body which has been subjected to thecutting step to a subsequent stage by changing the direction of theprocessed body at 90 degrees with respect to the transfer directionthereof is carried out. In this embodiment, a method of transferring theprocessed body 1 c of the laterally arranged rows of the elongatedstring-like materials 11 c, which are placed on the flat table 51 of thedirection changing unit 5, to a subsequent stage in the directioncrossing at 90 degrees the direction in which the processed body istransferred to the flat table 51 is used. Consequently, the processedbody 1 c of the longitudinally arranged rows of multiple elongatedstring-like materials 11 c of a in thickness, d in width and b in lengthare transferred to a subsequent stage.

After the transfer direction changing step finishes, the secondprocessing step for obtaining granulated materials by cutting thedirection-changed processed body in parallel with the processed bodytransferring direction to a predetermined width is carried out. Namely,the second processing step is a step (refer to FIG. 3) using the samesecond paired grooved rolls 6 a, 6 b as in the first processing step,and carried out by introducing the processed body 1 c between the secondpaired grooved rolls 6 a, 6 b, and cutting the processed body inparallel with the transfer direction thereof to a predetermined width cso as to obtain a multiplicity of granulated materials 11 d of a inthickness, c in width and b in length. Since the distance between freeends of opposed cutting edges 61 a, 61 b of the second grooved rolls 6a, 6 b, i.e. the distance between these rolls is zero in this step, theprocessed body 1 c is cut longitudinally at intervals c equal to thoseof adjacent cutting edges 61 a, 61 a. When the temperature of theprocessed body 1 c is maintained in the range of 70 to 130° C. in thiscase, preferable results are obtained since the cutting stability of theprocessed body 1 c is improved. When the multiple granulated materials11 d are discharged from the second grooved rolls 6 a, 6 b, it ispreferable to use scrapers (not shown) since the use thereof enables asmooth recovering operation to be carried out. The thickness a, width cand length b of the granulated materials 11 d are not limited to thosein this embodiment. These sizes are determined suitably in the range of,for example, 0.5 to 4 mm respectively by suitably selecting the distancebetween the rolling rolls, and the intervals, etc. of the cutting edgesof the grooved rolls used in the first processing step and secondprocessing step. The thickness a of the sheet type molding material 1 bincreases little by little as the material passes through the firstprocessing step and second processing step, so that the thickness a ofthe granulated materials obtained after the execution of the secondprocessing step is somewhat larger than that of the sheet type moldingmaterial 1 b. According to the first mode of embodiment, the moldingmaterial is compacted in the rolling step, so that a molding materialdifficult to be deformed even due to an impact and friction and the likewhich the material receives in a later step can be obtained. In thefirst processing step, a processed body of laterally arranged rows ofelongated string-like materials is obtained by a cutting operation. Inthe second processing step, a processed body of longitudinally arrangedrows of elongated string-like materials is cut into small pieces in thelongitudinal direction, so that granular molded materials of a uniformgrain size of a thermosetting resin composition can be obtained easily.In this embodiment, a long-term continuous granulated material producingoperation can be carried out, and a high productivity is attained.Moreover, fine powder does not occur during the transferring of thematerial between the processing stages, so that the yield of theproducts does not lower. Even when vibration of the products occursduring the transferring thereof after the manufacturing operationtherefor finishes, the products rarely encounters the occurrence of finepowder and problems concerning the environmental sanitation rarelyarise.

The method of manufacturing molded materials of a thermosetting resincomposition in a second mode of embodiment will now be described. Inthis second mode of embodiment, portions constituting differencesbetween this mode of embodiment and the first mode of embodiment will bemainly described. Namely, the portions of the second mode of embodimentconstituting the differences between the same mode of embodiment and thefirst mode of embodiment reside in the steps carried out in order whichinclude a second processing step for making a multiplicity of slitsafter the execution of such a transfer direction changing step asmentioned above in the transfer direction-changed processed body 1 c inparallel with the transfer direction to a predetermined width c andthereby obtaining a processed body of longitudinally arranged rows ofelongated string-like materials having longitudinal slits of apredetermined width, and a step of applying an external force to theprocessed body of the longitudinally arranged rows of string-likematerials obtained in the second step and thereby obtaining granulatedmaterials. Namely, the manufacturing apparatus used in the manufacturingmethod of the second mode of embodiment and that used in themanufacturing method of the first mode of embodiment are different fromeach other in the set value of the distance between the second groovedrolls 6 a, 6 b. In the second grooved rolls 6 a, 6 b used in the secondprocessing step in the second mode of embodiment, the distance betweenfree ends of opposed cutting edges 61 a, 61 b of the second groovedrolls 6 a, 6 b, i.e. the inter-roll distance is set to, for example,around 0.2 mm. Namely, when the processed body 1 c is introduced betweenthe two grooved rolls 6 a, 6 b in the second processing step in thisembodiment, the processed body 1 c is not cut off but longitudinallyslitted at intervals c in parallel with the processed body transferringdirection. This enables elongated string-like materials provided with amultiplicity of slits at predetermined intervals c, and having athickness a, a length b and a width d to be obtained. A coarselycrushing step for obtaining granulated materials by applying an externalforce to the processed body of longitudinally arranged rows of processedmaterials obtained in the second step is then carried out. In thecoarsely crushing step, the processed body of longitudinally arrangedrows of processed materials obtained in the second step is cooledusually to a temperature in the vicinity of room temperature, and anexternal force is then applied to the cooled processed bodies. Themethod of applying an external force to the processed bodies is notspecially limited. For example, a method using a hammer mill or anautomatic miniaturized mixer is included. According to this embodiment,effects identical with those in the first mode of embodiment aredisplayed. In addition, a processed body of laterally arranged rows ofelongated string-like materials is obtained by a cutting operation inthe first processing step, and processed bodies of longitudinallyarranged rows of elongated materials are slitted closely in thelongitudinal direction in the second processing step. Therefore, when anexternal force is applied to these processed bodies, granulatedmaterials are easily obtained.

The method of manufacturing molded materials of a thermosetting resincomposition in a third mode of embodiment will now be described.Concerning the third mode of embodiment, the portions thereof whichconstitute the differences between this mode of embodiment and the firstmode of embodiment will be mainly described. Namely, the differencesbetween the third mode of embodiment and the first mode of embodimentreside in a first processing step, which is carried out after theexecution of a sheet producing step, for making a multiplicity of slitsat predetermined intervals b in parallel with the direction in which asheet type material 1 b is transferred, and thereby obtaining a recessedand projecting sheet type processed body 1 c having a multiplicity oflongitudinal slits; a second processing step, which is carried out afterthe execution of a transfer direction changing step, for cutting theprocessed body, the transfer direction of which has been changed, inparallel with the transfer direction to a predetermined width, andthereby obtaining a processed body of laterally arranged rows ofelongated string-like materials having a multiplicity of lateral slits;and a final step for applying an external force to the processed body oflaterally arranged rows of processed materials obtained in the secondprocessing step, and thereby obtaining granulated materials. Amanufacturing apparatus used in the manufacturing method in the thirdmode of embodiment and that used in the manufacturing method in thefirst mode of embodiment differ from each other in a set value of thedistance between the first grooved rolls 3 a, 3 b. In the thirdembodiment, the distance between free ends of opposed cutting edges 31a, 31 b of the first grooved rolls 3 a, 3 b used in the first processingstep, i.e. the inter-roll distance is set to, for example, around 0.2mm. When the sheet type molding material 1 b is introduced between thetwo grooved rolls 3 a, 3 b in the first processing step in thisembodiment, the sheet type material 1 b is not cut off but slitted inparallel with the sheet type material transferring direction atintervals b. Consequently, longitudinally continuous recessed andprojecting sheet type material 1 c provided with a multiplicity oflateral slits at predetermined intervals b, and having a thickness a anda width d is obtained (refer to FIG. 4). After a cutting step and atransfer direction changing step have finished, a second processing stepis carried out in which the recessed and projecting sheet type materialof a in thickness and d in width having lateral slits arrangedlongitudinally at intervals b is cut off. The cutting operation in thesecond processing step is carried out by a method identical with thatused in the second processing step in the first mode of embodiment.Namely, the processed body 1 c is introduced between the two secondgrooved rolls 6 a, 6 b, and then cut in parallel with the processed bodytransferring direction to a predetermined width c to obtain a processedbody of laterally arranged rows of elongated string-like materials of ain thickness and c in width having a multiplicity of lateral slits. Acoarsely crushing step for applying an external force to the processedbody of longitudinally arranged rows of string-like materials obtainedin the second processing step, and thereby obtaining granulatedmaterials is then carried out. This coarsely crushing step is carriedout in the same manner as that in the second mode of embodiment.According to the invention of the third embodiment, effects identicalwith those obtained in the above-mentioned invention (1) are displayed.In addition, a sheet type processed body provided with a multiplicity ofslits in parallel with the transfer direction thereof so that the slitsare arranged at predetermined intervals is obtained in the firstprocessing step. In the second processing step, a sheet type processedbody is turned into a processed body of laterally arranged rows ofelongated string-like materials having lateral slits, granulatedmaterials are obtained easily when an external force is applied thereto.

The method of manufacturing molded materials of a thermosetting resincomposition in a fourth mode of embodiment will now be described. In thefourth mode of embodiment, the portions thereof constituting differencesbetween the same mode of embodiment and the third mode of embodimentwill be mainly described. Namely, the portions of the fourth embodimentconstituting the mentioned differences reside in a second processingstep, which is carried out after the execution of a transfer directionchanging step, for making a multiplicity of slits in a processed body,the transfer direction of which has been changed, in parallel with thetransfer direction at predetermined intervals, and thereby obtaining asheet type processed body having slits of a checker pattern. Amanufacturing apparatus used in the manufacturing method in the fourthmode of embodiment and that used in the manufacturing method in thefirst mode of embodiment differ from each other in a set value of thedistance between the first grooved rolls 3 a, 3 b and that betweensecond grooved rolls 6 a, 6 b used in the second processing step. Thedistances between free ends of opposed cutting edges of the firstgrooved rolls 3 a, 3 b and second grooved rolls 6 a, 6 b used in thefourth embodiment, i.e. inter-roll distances are all set to, forexample, around 0.2 mm. When a processed body 1 c, which has beensubjected to the same first processing step, cutting step and transferdirection changing step as in the third mode of embodiment, isintroduced between the paired grooved rolls 6 a, 6 b, the processed body1 c is formed into a sheet type material of c in width and b in lengthhaving slits of a checker pattern (FIG. 5). According to thisembodiment, the effects identical with those in the third mode ofembodiment are displayed. In addition, a sheet type processed bodyhaving a multiplicity of slits extending in parallel with the transferdirection thereof at predetermined intervals is obtained in the firstprocessing step. When an external force is applied to the processed bodyin the second processing step so as to make slits minutely in thelongitudinal direction and thereby form slits of a checker patterntherein, granulated materials are obtained easily.

The thermosetting resin compositions used in the present inventioninclude a thermosetting resin by itself or a resin compositioncontaining at least a thermosetting resin and a curing agent. Thethermosetting resins include phenol resins, such as resol phenol resinand novolak phenol resin, etc., epoxy resin, polyimide resin, polyesterresin, etc. When the thermosetting resin in use is a novolak phenolresin, hexamethylene tetramine is usually used as a curing agent. Theresin composition may further contain a filler. As the filler, aninorganic substance, such as glass fiber, calcium carbonate, clay, mica,silica, etc., and an organic substance, such as wood flour, pulp, wovenfiber, thermosetting hardened resinous substance, etc. are enumerated.

In the apparatus 10 for manufacturing molded materials of athermosetting resin composition according to the present invention, thefirst grooved rolls 3 a, 3 b and second grooved rolls 6 a, 6 b whichform the first processing unit and second processing unit can also beselectively replaced with a combination shown in FIG. 6 of a groovedroll 3 a and a flat roll 3 b having a cutting edgeless flat surface 32b, or a combination of a grooved roll 6 a and a flat roll 6 b having acutting edgeless flat surface 62 b besides the combination of the modeshown in FIG. 1. In such cases, the regulating of the cutting edges ofthe grooved rolls and the managing of the cutting edges and the functionof scrapers are done easily. Although the shape of the cutting edges orslitting edges of the first grooved rolls 3 a, 3 b and second groovedrolls 6 a, 6 b is not specially limited, these edges may also be shapedlike a cutting edge 31A (FIG. 7) including cutting edges 31 a, 31 b, 61a, 61 b the free end portions of which have an acute cross section, andthe depth h of the chip spaces of which is larger than about a/2; acontact cutting edge 31B (FIG. 8) including cutting edges 31 a, 31 b, 61a, 61 b which have a rectangular cross section, chip spaces of a depth hlarger than a, and an edge width m larger than a chip space width n, andwhich are formed so that one side cutting edge portions 31 a, 61 a andthe chip spaces of the other side cutting edge portions 31 b, 61 b areopposed to each other; and an engagement slitting edge 31 c (FIG. 9)including cutting edges 31 a, 31 b, 61 a, 61 b which have a rectangularcross section and a chip space width q larger than an edge width p, andwhich are formed so that one side cutting edge portions 31 a, 61 a andthe chip spaces of the other side cutting edge portions 31 b, 61 b areopposed to each other. The free end of the cutting edge 31A of FIG. 7may be rounded or have a flat surface. In any of the combinations ofgrooved rolls of FIG. 7 to FIG. 9, one grooved roll may be a flat rollhaving a flat surface.

EMBODIMENTS Embodiment 1

The same apparatus 10 for manufacturing molded materials of athermosetting resin composition as shown in FIG. 1 was used. First, 34parts by weight of powdered novolak-based phenol resin, 6 parts byweight of powdered hexamethylene tetramine as a curing agent, a total of55 parts by weight of inorganic fillers including 45 parts by weight ofglass fiber chops and 10 parts by weight of clay, and a total of 5 partsby weight of other additive agents including 2 parts by weight ofcalcium hydroxide as a curing accelerator, 2 parts by weight of stearicacid as a mold lubricant and 1 part by weight of carbon black as acoloring agent were mixed in a blender. The resultant mixture wasmelt-kneaded by a heating roll the surface temperature of which was setto 100° C. to obtain a molding material. This molding material wasimmediately introduced between rolling rolls having a clearance of 2 mmand temperature-regulated to 40° C. so as to roll the material. Therolled material was then passed between two first grooved rolls havingcontinuous scrapers, a chip space width of 2 mm and a clearance (rollclearance) of 0 mm between the free ends of opposed cutting edges, andformed into a processed body (rigid frame-like body) of laterallyarranged rows of elongated string-like materials. The processed body(rigid frame-like body) of laterally arranged rows of elongatedstring-like materials was cut to a length of 400 mm, and the transferdirection of this material was thereafter changed at 90 degrees by adirection changing unit, the processed body having then been passedbetween paired second grooved rolls provided with continuous scrapers,and having a chip space width of 2 mm and a clearance (roll clearance)of 0 mm in width between free ends of opposed cutting edges thereof tomanufacture granular molded materials of a phenol resin composition.First grooved rolls and second grooved rolls the shape of which was thesame as that of the grooved rolls shown in FIG. 7 were used.

The raw molded materials thus obtained were processed in aself-revolving type miniaturized mixer for 15 minutes. The resultantmaterials were sieved by using a vibrating screen to ascertain the grainsize distribution thereof. The results showed that the materials of agrain size of 1 to 2 mm were contained at 95%, and that fine powder ofnot larger than 180 μm did not substantially occur.

Embodiment 2

The same raw molding materials as were used in Embodiment 1 were mixedin a blender, and the resultant materials were melt-kneaded by a heatingroll. The kneaded product was rolled by immediately introducing the samebetween rolling rolls temperature-regulated to 40° C. and having arolling clearance of 2 mm. The rolled product was introduced betweenpaired first grooved rolls provided with continuous scrapers, and havinga chip space width of 2 mm and a clearance (roll clearance) of 0.2 mm inwidth between free ends of opposed cutting edges to manufacture a sheettype material having longitudinal slits of 2 mm in width. This sheettype material was cut to a length of 400 mm with cutter, and thetransfer direction of the material thus cut was then changed at 90degrees by a direction changing unit. The resultant material wasintroduced into a clearance (roll clearance) of 0.2 mm in width betweenfree ends of opposed cutting edges of paired second grooved rolls withscrapers and with a chip space width of 2 mm to obtain a sheet typemolded material of a phenol resin having slits of a checker pattern 2 mmsquare.

The sheet type molded material thus obtained which had slits of achecker pattern was placed in a self-revolving miniaturized mixer, andprocessed for 15 minutes to obtain granulated materials. These materialswere then sieved by using a vibrating screen to ascertain the grain sizedistribution thereof. The results showed that the granulated materialscontained 93% of granulated materials of 1 to 2 mm in grain size andaround 2% of fine powder of not larger than 180 μm in grain size.

EFFECTS OF THE INVENTION

According to the present invention, the molding material can becompacted in the rolling stage, and formed into a molding material whichwas difficult to be deformed even by an impact and a frictional forcewhich the molding material receives in a subsequent stage. Even in thefollowing first processing stage and second processing stage, granulatedmaterials are obtained in a cutting process or a slitting process.Therefore, the rate of occurrence of fine powder which was not lowerthan 10% in a related art production system can be reduced to as low asseveral percent, and granulated materials of a desired uniform grainsize can be obtained stably for a long period of time. Accordingly, theyield of the products can be improved greatly, and preferable effectsconcerning the environmental sanitation are obtained. Since theequipment is simple and compact, the plant and equipment investment canbe held down to a low level.

1. An apparatus for manufacturing molded materials of a thermosettingresin composition by granulating a material of the thermosetting resincomposition, comprising rolling rolls for rolling the molding materialin a molten state into a sheet type material of a predeterminedthickness, a first processing unit for processing the rolled sheet typematerial into a processed body of laterally arranged rows of elongatedstring-like materials of a predetermined width, or into a sheet typeprocessed body having a multiplicity of slits extending in parallel withthe sheet type material transferring direction, a cutter for cutting theprocessed body, which has been obtained by the first processing unit, inthe processed body transferring direction to a predetermined length, adirection changing unit for changing the transfer direction of theprocessed body, which has been cut with the cutter, at 90 degrees withrespect to the longitudinal cutting line or slitting line of theprocessed body, and a second processing unit for cutting or slitting theprocessed body, the transfer direction of which has been changed by thedirection changing unit, in parallel with the transfer direction thereofto a predetermined width.
 2. An apparatus for manufacturing moldedmaterials of a thermosetting resin composition according to claim 1,wherein the first processing unit and second processing unit are groovedrolls respectively.
 3. An apparatus for manufacturing molded materialsof a thermosetting resin composition according to claim 1, wherein therolling rolls are provided with scrapers for forcibly peeling off therolled sheet type processed body therefrom.
 4. An apparatus formanufacturing molded materials of a thermosetting resin compositionaccording to claim 1, wherein the first processing unit and secondprocessing unit are provided with scrapers for forcibly peeling off theprocessed body or bodies, which are discharged from the respectiveprocessing units, from the rolls.